Electrodes for orthotic device

ABSTRACT

According to various embodiments of the invention, an electrode for an orthotic device, comprises a backing layer having an outer surface allowing the electrode to be attached to an orthotic device; conductive layer configured to receive and distribute an electrical current according to an electrophysical modality; an interface layer configured to conform to a wearer&#39;s anatomy and to conduct the electrical current from the conductive layer to the wearer&#39;s anatomy; and a connection member attached to the conductive layer and configured to electrically couple with an electrical contact disposed on the orthotic device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of and claims the priority ofU.S. application Ser. No. 12/468,794 filed May 19, 2009, which claimspriority from U.S. application Ser. No. 10/591,966 filed Sep. 7, 2006,which claims priority from PCT Application Serial Number PCT/US05/08010filed Mar. 10, 2005, which claims priority from New Zealand ApplicationSerial Number NZ531705 filed Mar. 10, 2004, each of which is herebyincorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates generally to orthotic devices, and moreparticularly, some embodiments relate to electrodes adapted to provideelectrostimulation and to conform to a wearer's anatomy

DESCRIPTION OF THE RELATED ART

Orthotic devices generally include a substantially rigid biomechanicalelement that forms the basis of the skeletal support that is requiredfor the majority of these devices, which include braces, supports andsplints.

The human knee generally comprises an articulated joint between thethigh and the calf muscles that supports the weight of the human bodywhile the person is standing, walking or running. The knee joint isprimarily held together by four ligaments; namely, the anterior andposterior cruciate ligaments and the medial and lateral collateralligaments. The knee joint can be overly weakened by injuries arising outof cartilage damage and ligament strain, which may be caused, by sportsinjuries, as well as from everyday exercising, or physiological problemssuch as osteoarthritis. Thus, the human knee is subjected to a varietyof stresses and strains particularly during running and jumpingmovements. Athletes, in particular, are apt to incur a knee injury as aresult of a blow to the knee or to a twisting of the knee, which cancommonly occur in various contact sports or high stress sports, such asskiing.

There are a variety of knee braces available on the market or throughhealthcare providers. These range from braces that tend to totallyimmobilize the knee to flexible elastic bandages that are intended toprovide some flexibility while eliminating lateral movement of theligaments that support the knee. Some of these are intended to be wornas a relatively permanent device for long-term wear or braces that areintended to be worn for a short period of time during overly strenuousfor a short period of time for a weakened knee. The braces have as theirprimary object to allow for pivoting the knee while preventing anyunnatural movement that may aggravate the knee ligaments. Some bracesare meant to provide a constant or variable “unloading” force on theknee joint to alleviate pain, such as pain caused by Osteoarthritis.While the braces are intended to allow for a natural movement of theknee joint while a person undergoes walking, running, jumping, skating,various other athletic activities, they are also intended to preventsudden movement of the upper and lower legs to one side or the other andto prevent twisting or rotation of the lower leg relative to the upperleg about the vertical axis, and/or to provide a pain-relieving force tothe joint.

Typically, the knee braces are held in place by flexible straps, whichwrap about the user's thigh and calf above and below the knee,respectively. In this manner, the rigid hinge of the knee brace remainspositioned on either side of the user's knee so as to mimic the hingedjoint of the knee. However, it is not uncommon for the user's bodilymotions to cause the flexible straps to move relative to the person'sleg, thereby misaligning the knee brace with respect to the knee. Thismovement of the brace straps with respect to the user not only causemisalignment and therefore misapplication of the orthotic device, butalso cause irritation of the user's skin by this unintended rubbing.

Orthotic devices must engage effectively with soft tissue in order toprovide the desired support. In many parts of the body the soft tissuewill move, for example by expanding or contracting as result of musclemovement. As a soft tissue changes shape, parts of the skin lose contactwith the liner of the orthotic device. This reduced contact with theliner can cause the orthotic device to lose position, or move relativeto the user and therefore become ineffective. Typical devices providemeasures for tightening the brace to maintain contact. This causesdiscomfort, prevents the skin from breathing, and can irritate the skinabout the edges of the device and the liner.

The objective of any rigid knee brace is to exert a predictable force onthe user's underlying skeleton. In particular, the objective is to exerta force on the tibia with respect to the femur in the user's body massabove the knee. By definition, knee braces are applied to soft tissuelying between the brace and the user's skeleton. The rigid element mayinclude some form of liner that contacts the body of the user. The linermay have an outer fabric that is designed to contact the user's skindirectly or, alternatively, to engage with clothing that a user may bewearing about the part of the anatomy to which the orthotic device is tobe attached. Soft tissue is mobile and moves in a cycle corresponding toa user's gait, whether it be through running, walking or other physicalmovement common to the human knee. The most mobile soft tissue is thequadriceps mechanism lying in front of the femur in the anterior thighregion. The central reference point for a knee brace is the knee jointline. In construction, an orthotic device such as a knee brace would usea joint mechanism, which mimics the movement of the joint to besupported, such as the knee, which is not just a simple hinge. Sinceeach user's body shape is unique, the interface between the orthoticdevice and the user's leg cannot be predetermined in the manufacture ofsuch a device.

Degenerative joint disease, osteoarthritis, and other joint diseases orinjuries may be treated through various methods of electricalstimulation. Surface electrical stimulation (SES) treats theseconditions using sub-sensory electrical pulses. Other methods ofelectrostimulation include Neuromuscular Electrical Stimulation,Interferential Stimulation, High Volt Galvanic Stimulation,Electromagnetic and Pulsed Electromagnetic Field Stimulation,Transcutaneous Electrical Nerve Stimulation, Transcutaneous ElectricalStimulator for Arthritis (TESA), and Micro Current ElectricalStimulation.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

According to various embodiments of the invention, an electrode for anorthotic device, comprises a backing layer having an outer surfaceallowing the electrode to be attached to an orthotic device; aconductive layer configured to receive and distribute an electricalcurrent according to an electrophysical modality; an interface layerconfigured to conform to a wearer's anatomy and to conduct theelectrical current from the conductive layer to the wearer's anatomy;and a connection member attached to the conductive layer and configuredto electrically couple with an electrical contact disposed on theorthotic device.

According to an embodiment of the invention, an orthotic device system,comprises a first support member adapted to be secured to a portion of afirst side of a joint; a second support member adapted to be secured toa second side of the joint; a means of connecting the first supportmember to the second support member a conformable, discrete linersegment attached to the first or second support member configured toprovide an attachment location for a first electrode; a first electrodedisposed on the liner segment configured to contact a first area nearthe joint; a second electrode configured to contact a second area nearthe joint; and an electrostimulation unit in electrical contact with thefirst and second electrodes and configured to provide an electrophysicalmodality to the leg; wherein the first or second electrode comprises abacking layer having an outer surface allowing the electrode to beattached to an orthotic device; a conductive layer configured to receiveand distribute an electrical current according to an electrophysicalmodality; an interface layer configured to conform to a wearer's anatomyand to conduct the electrical current from the conductive layer to thewearer's anatomy; and a connection member attached to the conductivelayer and configured to electrically couple with an electrical contactdisposed on the orthotic device.

Other features and aspects of the invention will become apparent fromthe following detailed description, taken in conjunction with theaccompanying drawings, which illustrate, by way of example, the featuresin accordance with embodiments of the invention. The summary is notintended to limit the scope of the invention, which is defined solely bythe claims attached hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention, in accordance with one or more variousembodiments, is described in detail with reference to the followingfigures. The drawings are provided for purposes of illustration only andmerely depict typical or example embodiments of the invention. Thesedrawings are provided to facilitate the reader's understanding of theinvention and shall not be considered limiting of the breadth, scope, orapplicability of the invention. It should be noted that for clarity andease of illustration these drawings are not necessarily made to scale.

Some of the figures included herein illustrate various embodiments ofthe invention from different viewing angles. Although the accompanyingdescriptive text may refer to such views as “top,” “bottom” or “side”views, such references are merely descriptive and do not imply orrequire that the invention be implemented or used in a particularspatial orientation unless explicitly stated otherwise.

FIG. 1 is a front elevation of a knee brace according to the presentinvention;

FIG. 2 is a rear elevation of the brace of FIG. 1;

FIG. 3 is a partial plan view of the brace of FIG. 1;

FIG. 4, consisting of FIGS. 4A and 4B, is a plan view and sideelevation, respectively of a liner element of the present invention;

FIG. 5, consisting of FIGS. 5A and 5B, is a plan view and sideelevation, respectively of an alternative embodiment of the linerelement;

FIG. 6, consisting of FIGS. 6A and 6B, is a front elevation and rearelevation, respectively, of a liner segment having electrophysicalmodality according to the present invention;

FIG. 7 is a perspective view of an orthotic device adapted for receivinga segmented tibial liner element;

FIG. 8 is a view partially in section of the orthotic device in FIG. 7illustrating attachment of the segment and tibial liner element;

FIG. 9 is a cross section view taken through line IX-IX in FIG. 7;

FIG. 10 is a cross section view similar to FIG. 9 and also illustratingattachment of the segmented tibial liner;

FIG. 11 illustrates a preferred embodiment of a segmented active tibialmanagement liner;

FIG. 12 is a detail view of the orthotic device in FIG. 7 andillustrating an alternative embodiment of a segmented tibial liner,

FIG. 13 illustrates an embodiment of a segmented active tibialmanagement liner,

FIG. 14 is a top plan view of the segmented tibial liner element in

FIG. 13;

FIG. 15 is a side plan view of the segmented active tibial liner elementin FIG. 13;

FIG. 16 is a front plan view of a segmented tibial liner;

FIG. 17 is a top plan view of the segmented tibial liner in FIG. 16;

FIG. 18 is a front plan view of a segmented tibial liner receptacleplate, such as on an orthotic device as shown in FIG. 7;

FIG. 19 illustrates variable attachment positions for the segmentedtibial liner as shown in FIGS. 16 and 17;

FIG. 20 is a cross sectional view of an orthotic device similar to theorthotic device shown in FIG. 7 illustrating a further embodiment of asegmented tibial liner;

FIG. 21 illustrates an embodiment of a chock for use with the segmentedtibial liner in FIG. 20;

FIG. 22 is a cross section view showing a segmented tibial linerreceptacle plate in and alternative manner of attaching a segmentedtibial liner; and

FIG. 23 is a cross section view similar to FIG. 22, showing a stillfurther embodiment of a manner of attaching a segmented tibial liner.

FIG. 24 illustrates a side perspective view of an orthotic device withelectrophysical modality components, according to an embodiment of theinvention.

FIG. 25 is a lateral plan view of a knee brace assembly according to anembodiment of the invention.

FIG. 26 is a lateral perspective view of a knee brace assembly worn on auser's leg according to an embodiment of the invention.

FIGS. 27A and 27B illustrate two examples of thigh cuffs withelectrostimulation units according to embodiments of the invention.

FIG. 28 shows a plan view and a lateral side view of anelectrostimulation pad electrode according to an embodiment of theinvention.

FIG. 29 illustrates a side view of an electrode disposed on an orthoticdevice according to an embodiment of the invention.

FIG. 30 is a plan view of an electrode disposed on a segmented lineraccording to an embodiment of the invention.

FIG. 31 illustrates an electrode having a plurality of connectionportions according to an embodiment of the invention.

FIG. 32 illustrates a cross-sectional view of an electrode according toan embodiment of the invention.

FIG. 33 illustrates a plan view of a further electrode according to anembodiment of the invention.

FIG. 34 illustrates a cross-sectional view of an electrode according toan embodiment of the invention.

FIG. 35 illustrates a plan view of nesting electrodes according to anembodiment of the invention.

FIGS. 36A, 36B, and 36C illustrate lateral views of an adjustableelectrode and liner according to an embodiment of the invention.

FIGS. 37 illustrates lateral view of an adjustable electrode and linerwith contact element according to an embodiment of the invention.

The figures are not intended to be exhaustive or to limit the inventionto the precise form disclosed. It should be understood that theinvention can be practiced with modification and alteration, and thatthe invention be limited only by the claims and the equivalents thereof.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

Referring now to the drawings in detail, wherein like referencecharacters refer to like elements, there is shown in FIG. 1 a knee brace10 according the present invention. The invention will be described withreference to a knee brace; however, it will be understood that theinvention is also applicable to other orthotic devices such as an ankle,back, arm, shoulder, or wrist brace, and other devices for relievingpain in any body portion of the user. Although this invention will bedescribed by way of example and with reference to preferred embodimentsthereof, it is to be understood that modifications or improvements maybe made thereto without departing from the scope or spirit of theinvention. It should be noted that various changes and modifications tothe presently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. It is, therefore, intendedthat such changes and modifications be included within the presentinvention.

Referring to FIG. 1, a knee brace 10 is shown having a biomechanicalsupport comprising two substantially rigid arms, 13 and 16, which arejoined together by a hinge assembly 19. Connected to the rigid arms areupper and lower structures 22 and 25, respectively which, together withstraps 28 and 31 are used to form a primary engagement with the user'sleg above and below the knee 34. This engagement can be augmented byfurther straps 37 and 40. The hinge assembly 19 has a predeterminedrange of movement corresponding to the desired range offlexion/extension of the knee of the user. The upper and lower supportstructures 22, 25 are generally referred to as cuffs.

The upper cuff 22 is adapted to be secured to the user's thigh (femur)and the lower cuff 25 is adapted to be secured to the lower leg or calf(tibia). In this way the hinge assembly 19 is placed adjacent the axisof the user's knee joint, thereby allowing the knee brace 10 tosubstantially mimic the bending of the user's knee as the user goesabout his or her otherwise normal activities. In the preferredembodiments, upper and lower cuffs 22, 25 comprise adaptive supportstructures that are constructed from a semi-rigid material such as athermoplastic elastomer or a thermoplastic rubber.

Furthermore, the preferred embodiments may include a rigid material 43that is integrally molded into upper and lower structures 22, 25, or isalternatively fixedly attached to the structures. Rigid material 43 hasa greater rigidity than the semi-rigid material from which upper andlower structures 22, 25 are moulded, and is preferably malleable. In thepreferred embodiments, rigid material 43 comprises a sheet aluminummaterial which has an appropriate thickness (for example, on the orderof about 1-2 two millimetres thick), or other deformable metal, so thatit may be easily shaped by the user using his or her hands to assist theadaptive material from which the structures 22, 25 are manufactured togenerally conform to the portion of the anatomy to which the device isto be attached.

Attached directly or indirectly to the upper and lower cuffs 22, 25 is aliner arrangement 46, which may take a variety of different forms. Inthe most preferred embodiments illustrated in the figures, the linerarrangement 46 takes the form of a plurality of discreet segments 49.Each segment 49 preferably comprises a resilient material, which may beformed by moulding for example, cutting or otherwise shaping anappropriate material. Alternatively, in the most preferred embodimentseach segment 49 comprises a material such as a soft resilient foam andan outer layer of material which is intended to contact human skin, suchas material sold under the trade name DRY-X. This material is preferredfor its property of combining a highly durable nylon material with amicro-porous waterproof and breath-able coating, which allowsperspiration of the user to escape through the fabric while preventingmoisture from entering the brace so as to provide a comfortable feel forthe user of the brace 10.

Each segment 49 may also have properties of resilience provided by afluid, such as air or water, or other substances such as gels. Thesegments 49 may include a fluid or gel which can be heated or cooled yetis still resilient and conforming, so as to provide an additionaltherapeutic benefit to the user. Because of their resilience, thesegments 49 adapt to the particular leg shape and musculature of theuser. This enables the knee brace 10 to accommodate a variety ofmuscular shapes and sizes, as the resilient segments 49 readily conformto the user's thigh and calf as the cuffs 22, 25 are secured about theuser's leg. The brace 10 can be made snug to the user's leg withouthaving to over-tighten the straps 28, 31, 37 and 40. Moreover, the DRY-Xmaterial, or other breathable fabric, prevents excess moisture orsweating of the user's leg between the skin and the brace.

The segments 49 may be engaged with upper and lower cuffs 22, 25 byproviding those structures with a selected lining, such as a hook andloop fastener arrangement, commonly referred to as “VELCRO®.” One halfof the VELCRO® material is provided on the rear portion of each segment49 and can then be engaged with the other half VELCRO® on the upper andlower cuffs 22, 25 so that the segments can be secured in the desiredposition. This construction has a further advantage that the segmentsmay be repositioned depending upon the requirements of the user.Furthermore, segments of a number of different shapes and sizes havingdifferent properties (for example varying properties of resilience orhardness) may be provided and the user may substitute segments orrearrange the location of segments so that a comfortable and effectivefit is achieved.

As another alternative, the segments may advantageously be linkedtogether. For example, in FIGS. 4 and 5 segments 52 are illustrated asbeing interconnected by being placed on a substantially planar substrate55. As can be seen, each segment 52 protrudes, so that when a rearsurface of substrate 55 is affixed to support structure 22, 25 forexample, the segments 52 make contact with the body of the user. Asdiscussed above, the segments 52 may also be provided with varyingproperties, for example varying size (including varying height ofprotrusion), varying properties of resilience or support, and varyingposition.

The design of the segments can also be such as to facilitate skeletalgrip, quite apart from grip to soft flesh or pure arrangement for usercomfort. Therefore, for example the interconnected segments illustratedin FIGS. 4 and 5 may be provided in a knee brace 10 to provide enhancedskeletal grip, for example gripping the tibia.

Turning to FIG. 6, yet another application of the invention can bedescribed with reference to segment 58 which on a reverse side caninclude a VELCRO® attachment 61 to enable the segment 58 to be connectedto the support structure 22, 25 of the orthotic device 10, as describedabove. However, on the side of the segment 58 that contacts the body ofthe user, the segment includes one or more electrodes 64 which aresupplied with electrical energy by one or more conductors 67. Theconductors 67 are connected to an electrical source (not shown) such asa portable and lightweight battery pack that can easily be carried onthe user's body. By supplying electrical energy in the desired form, thesegment 58 can provide Electrophysical Modality such as musclestimulation, for example stimulating quadriceps muscles in the user'sknee, and provide pain relief such as that commonly known as TENS. Eachsegment (or selected segments) may include one electrode 64, which formsa circuit with another electrode (or electrodes) on other segments 58.

TENS is typically produced through high frequency electrical stimulationof the nerve, which disrupts the pain signal so that the pain is nolonger felt. Although the exact mechanism is not yet known, it isbelieved that TENS works by two different ways. First, electricalstimulation of the nerve fibers can block a pain signal from beingcarried to the brain. If the signal is blocked, pain is not perceived bythe user. Second, the human body has its own mechanism for suppressingpain; it does this by releasing natural chemicals, called endorphins, inthe brain which act as analgesics. TENS may activate this mechanism. Byusing these electrical pulses to stimulate the nerve endings at or nearthe site of the pain, the user feels diminished pain that is replaced bya tingling or massage-like sensation. The electrical power and circuitryfor providing the TENS stimulation can be provided in a small andrelatively lightweight package (not shown) which can be worn on theusers hip, or directly on the orthotic device, depending on itscomplexity and size. Thus, the orthotic device 10 of the presentinvention not only provides the desired support for the user's otherwiseweakened knee, but also provides a therapeutic benefit to the user's legmuscles and internal support structures.

One purpose of segmentation is to enhance functionality. Segmentationenables a degree of customization of the interface of the orthoticdevice with an individual's anatomy so as to achieve better grip andfit. A further function of segmentation provides for better control ofcomponents, including electrode components. Each segment of the linercan be viewed as an individual component, and after considering thesurface anatomy and characteristics of the tissue interface,customization of a segment provides solutions to variable shape, tissueturgor, soft tissue mobility, and the like. Additional solutions are theincorporation electrodes for physiological modalities, e.g., TENS.

As will be described in more detail hereinafter with respect to FIGS.7-23, an adjustable liner, or adjustable portions, e.g., segmentsthereof, can provide multiple solutions to the problem of differentanatomy profiles. In general, segments of an adjustable liner can beconfigured to enhance fit, in effect being customizable for a particularindividual. Embodiments of the adjustable liner can include segmentsthereof which are individually adjustable to suit specific activitylevels in individual anatomy to insure optimum control of movement inrotation of portions of the anatomy.

FIGS. 7-23 illustrate certain such embodiments of the invention in thecontext of a practical example of an application for an adjustable lineraccording to the invention. Specifically, embodiments of the adjustableliner are illustrated as components of the tibial support member, orcuff, of a knee a brace which interfaces with the anterior border of thetibia (i.e., the shin). The purpose of such a brace is to hold the tibiain position and to prevent it from subluxing (i.e., slipping forward orback or to either side or rotating). To accomplish this purpose, maximumgrip is desirable. There is a variety of anatomical shapes in anypopulation group, and frequently a difference between male and femaleprofiles in the anterior tibial border region. The adjustable liner, oradjustable segments thereof, utilized in the tibial region to provide,for example, adjustment for these differences is referred tooccasionally hereinafter as an Active Tibial Management (ATM) system.

Although the following drawing figures illustrate, by way of example,such an adjustable liner, or adjustable segments thereof, specificallyadapted for positioning in the orthotic device adjacent the tibia of auser; the application for an adjustable liner according to the inventionis not limited to use in regard to only the tibia, but can besatisfactorily designed to be used with various other parts of theanatomy, and adjacent not only skeletal structure like the tibia, butalso soft tissue. The adjustable liner, and particularly adjustablesegment thereof, can be treated as an individual component, which can beindividually designed, after considering the surface anatomy andcharacteristics of the specific tissue interface, to provide solutionsto variable shape, tissue turgor, soft tissue mobility, and the like. Asmentioned previously, electrodes for physiological modalities can alsobe incorporated.

Referring now to FIG. 7, an orthotic device 70 is illustrated wherein alower portion 72 of the orthotic device is adapted to be locatedadjacent the tibia of a person's leg. Referring to FIG. 8, the lowerportion of the device is shown having an ATM back plate 75 including areceptacle, or slot 78, to receive an adjustable tibial liner pad 80 viaa rib 81 on the back surface of the adjustable liner 80. As can be seenin FIG. 7, the upper portion 83 of the orthotic device 70 can include anattachment point 85 for other adjustable and/or segmented liners oradaptive element attachments. In addition, upper attachment points 87for a femoral proximal strap (not shown) and lower attachment points 90for a gastrochnemius strap (not shown) can also be provided. Theadjustable liner 80 can preferably comprise a pair of arm segments, orcams 93, 96, which define a tibial crest alignment groove 99 therebetween. Each cam segment 93, 96 can be individually adjustable in avariety of ways. In this manner, the cam segments 93, 96 can bemanipulated to adjust the shape of the adjustable liner 80.

As shown better in FIGS. 8, 9 and 10, adjustable cams 93, 96 of thetibial liner 80 enable an individual, adjustable fit for specificactivity levels and individual anatomy types to ensure optimal movementand rotation of the tibia. The individually adjustable cams 93, 96enable adjustment on either side of the tibial crest 99 to ensureoptimum fit and conformity to an individual's anatomy.

FIG. 9 is a cross section view showing the receptacle, e.g., slot 78, inthe ATM back plate 75, and FIG. 10 shows the adjustable tibial liner 80secured against the ATM receptacle plate 75 with the rib 81 engaged inthe slot 78.

Referring now to FIG. 11, the three views illustrate how the adjustablecams 93, 96 are adjustable in a plurality of different ways. As theupper most view shows each cam 93, 96 on opposite sides of the tibialcrest 99, can be rotated forwards or backwards to adjust the fit.Additionally, as illustrated in the center view, both of the cams 93, 96can be adjusted towards each other, or away from each other, to increaseor decrease the pressure against the tibia as desired. Finally, thelower view illustrates how the cams 93, 96 can be adjusted to provideincreased pressure on only one side of the tibia, to fit an individual'sanatomy and to counteract rotation.

FIGS. 12 through 15 illustrate a further embodiment of an adjustabletibial liner 100, in which the adjustable liner 100 can comprise a pairof pad segments 103, 106 which can be adjusted similarly to the camsegments 93, 96 in the previously described embodiment of the adjustabletibial liner 80. In this present embodiment, the adjustable tibial liner100 can be secured to the ATM back plate 75 in the same fashion as theadjustable tibial liner 80 described previously, such as via a rib 108received in the receptacle, i.e., slot 78, in the ATM back plate 75.Each pad segment 103, 106 can be adjusted in the ways illustrated inFIGS. 13-15. As shown in FIG. 13, each pad segment 103, 106 can beindividually rotated (clockwise or counter-clockwise), either away fromor towards each other. Alternatively, a single pad may be rotated ineither such direction without adjustment of the other pad. FIG. 14 showsa second type of adjustment, toward or away from the tibia, which iscommon with the adjustable arm segments 93, 96 of the adjustable liner80, as shown in FIG. 11.

Referring to FIG. 15, the adjustable tibial liner 100 can additionallybe designed such that each pad segment 103, 106 incorporates a pneumaticbladder, to enable each pad segment 103, 106 to expand or shrink. Thisenables increased control of the individual pressure of each pad segment103, 106 to counteract tibial rotation, and to also provide a morecustomized fit relative to the individual's anatomy. As shown in FIG.15, each pad 103, 106 has a certain thickness, and by provision of apneumatic system for inflating and/or deflating each individual pad 103,106, the width “W” of each pad 103,106 can thereby be increased ordecreased to control the individual pressure each pad 103, 106 exerts onthe tibia.

Referring now to FIGS. 16, 17 and 18, a further embodiment of anadjustable tibial liner 120 is illustrated which can be similar to theadjustable tibial liner 80 in FIGS. 7-11. The tibial liner 120 includescam segments 123, 126 which can be individually adjustable, and whichdefine a tibial crest groove 129 there between. A difference is that theadjustable tibial liner 120 in FIG. 16 is attachable to an ATM backplate 132, such as shown in FIG. 18, via a hook and loop fastenersystem, e.g., VELCRO®. As shown in FIG. 17, a layer 135 of VELCRO®material can be provided on the back surface of the adjustable liner 120and can mate with cooperating portions 138 of VELCRO® provided on theATM plate 132 shown in FIG. 18.

Referring to FIG. 19, the three views show that the adjustable tibialliner 120 can be easily attached at a number of different positions onthe ATM plate 132, as enabled by the VELCRO® attachment system. Forexample, the adjustable liner 120 can be centered on the ATM plate 132as shown in the top view, or can be offset laterally (left to right) asshown in the center view, or can be offset vertically (up and down) asshown in the bottom view. Additionally, any combination of lateral andvertical offset is also possible.

Referring now to FIGS. 20 and 21, a further embodiment of an adjustabletibial liner 150 is illustrated, wherein the attachment of the liner 150to the ATM back plate, generally referenced at 162, can be similarlyaccomplished using a VELCRO® type fastener system as described above.The adjustable tibial liner 150 preferably includes individuallyadjustable cam segments 153,156 which define a tibial crest groove 159there between. FIG. 20 is a cross section view of an orthotic device,including the ATM back plate, i.e. at 162, which may be similar to thetibial cuff portion of the orthotic device illustrated in FIG. 18. Aswith the preceding embodiment, one layer (not shown) of VELCRO® materialis affixed to the ATM back plate 162 and a cooperating layer 165 of theVELCRO® material is attached to the mating side of the adjustable tibialliner 150.

Each cam segment 153, 156 can be adjustable in the same manner as thecam segments 83, 86 of the tibial liner 80 illustrated in FIGS. 7-11.Additionally, however, as can be seen in the two lower views of theadjustable tibial liner in FIG. 20, the positioning of the cam segments153, 156 can further adjusted using chocks 170, i.e., the wedge shapedmembers illustrated in FIG. 21. The chocks 170 are inserted between thecams 153, 156 and the ATM back plate to further adjust, and maintain,the position of the cam segments 153, 156.

As shown best in FIG. 21, the chocks 170 can be provided in differentsizes, and with different angles as shown in the three upper side viewsof chocks 171, 172 and 173 in FIG. 21. This enables accommodation ofvaried tibial profiles to customize the fit of the adjustable tibialliner 150, to an individual's anatomy. The chocks 170 can be attachedbetween either or both cams 153. 156 of the tibial liner 150 and the ATMback plate via a VELCRO® type fastener arrangement as describedpreviously. As illustrated, one side of the chock 170 has a layer 175 ofVELCRO® material to attach which cooperates with a mating layer 165 ofVELCRO® material on the back of the adjustable tibial liner 150.Additionally, the opposite side of the chock 170 has another layer 178of VELCRO® material which cooperates with the layer (not shown) ofVELCRO® material provided on the ATM back plate.

Referring now to FIGS. 22 and 23, further embodiments of adjustabletibial liners 180 and 190 are illustrated attached to an ATM back plate188 (shown in cross section). As shown in both FIGS. 22 and 23, theadjustable tibial liners 180 and 190 can be rigidly attached to the ATMback plate 188, for example by a fastener 189, such as a screw or rivet.Each adjustable tibial liner 180, 190 includes individually adjustablecam segments (182, 184 and 192, 194) which define a tibial crest groove(186 and 196) there between.

FIG. 22 illustrates a pair of spacers 187 provided intermediate each camsegment 182, 184 of the adjustable tibial liner 180 and the ATM backplate 188. The spacers 187 can be individually adjusted as to both theposition and size thereof to maintain the adjustable tibial liner 180 ina particular position, or configuration, after initial adjustment.

As shown in FIG. 23, pneumatic elements 197 could also be providedinstead of, or in combination, with spacers. The pneumatic elements 197are positioned intermediate each cam segment 192, 194 of the adjustabletibial liner 190 and the ATM back plate 188. The pneumatic elements 197can be individually inflated, and deflated, to adjust the shape of theliner 190, and/or the positioning of each cam segment 192, 194 toprovide individualized fit and activity-specific levels of tibialcontrol, as described previously in regard to other embodiments of theadjustable tibial liner.

FIG. 24 illustrates a side perspective view of an orthotic device withelectrophysical modality components, according to an embodiment of theinvention. The illustrated orthotic device comprises a knee brace 201with two electrostimulation pads 204 and 205. Electrostimulation pads204 and 205 may be used in conjunction with electrostimulationcontroller 208 to provide electrophysical modalities. Suchelectrophysical modalities might include, for example Surface ElectricalStimulation (SES), Neuromuscular Electrical Stimulation (NES/NMES),Interferential Stimulation (IS/IF), High Volt Galvanic Stimulation(HVGS), High Volt Pulsed Current (HVPC), Electromagnetic and PulsedElectromagnetic Field Stimulation (EFS and PEFS/PEMF), TranscutaneousElectrical Nerve Stimulation (TENS), Transcutaneous Electrical JointStimulation (TEJS), Transcutaneous Electrical Stimulator for Arthritis(TESA), or Micro Current Electrical Stimulation (MCES).Electrostimulation module 208 is configured to provide theelectrostimulation voltages and currents to the leg via theelectrostimulation pads.

In various embodiments, the electrostimulation pads may comprise variousmeans to provide electromagnetic fields to a wearer's anatomy. Inparticular embodiments, electrostimulation pads 204 and 205 compriseresilient or conformable electrodes, such as electrodes composed ofconductive fabrics, gels, polymers, liquids, or colloids. Suchelectrodes allow electrical stimulation to be applied directly to theskin and through the tissue of a wearer while allowing theelectrostimulation pads to conform to the wearer's anatomy. For example,a particular electrode might be comprised of an isotropically conductingpolymer bladder filled with a conducting fluid configured such that,when the knee brace is worn, the constriction of the knee brace causesthe polymer bladder to expand normal to the axis of constriction suchthat a large conducting surface is formed at the wearer's skin. In otherembodiments, the electrode may be constructed of thin layers ofconductive and non-conductive materials, resulting in a very low-profilecomponent that easily conforms to the wearer's anatomy.

Such electrostimulation pads may be coupled to segmented or adjustableliners as described herein. Accordingly, these electrophysical segmentsmay be removable and adjustable in position and angle depending on thewearer's needs and conditions. For example, such electrostimulation padsor segments may be adjustable to improve engagement of the device withthe user's anatomy. As another example, in the embodiment illustrated inFIG. 24, a first electrostimulation segment 205 disposed on band 203,which is configured to wrap around a user's knee, and a secondelectrostimulation segment 204 is disposed on the upper rigid portionwithin liner 202. In this embodiment, electrostimulation segment 205 maycomprise a conductive fabric or flexible conductive polymer such thatband 203 is able to conform to the anatomy of a user's knee andelectrostimulation segment 204 may comprise a semirigid, resilientelement to structurally support the rigid upper portion of the kneebrace. For example, electrostimulation segment 204 might comprise arigid metal conducting element coupled to a conforming conductive pad,such as an electrically conducting gel. The use of SES in thisembodiment might comprise transmitting a current from electrostimulationpad 205 to electrostimulation pad 204 such that an electrical signal istransmitted from the knee or lower leg to the thigh.

In other embodiments, further electrostimulation segments might beprovided according to the desired electrophysical modality. For example,in a knee brace configured to apply interferential stimulation, a secondelectrostimulation segment (not shown) may be disposed on the oppositesurface of band 203 such that electromagnetic radiation emitted byelectrostimulation segment 205 and the second electrostimulation segmentconstructively interfere at a predetermined location within a user'sknee.

In various embodiments, the electrostimulation controller 208 may beconfigured such that multiple electrophysical modalities may be applied.For example, in the embodiment illustrated in FIG. 24, a thirdelectrostimulation pad may be disposed on the posterior portion of band203 such that TENS may be applied between electrostimulation segments204 and 205 during a first time interval and interferentialelectrostimulation may be applied between electrostimulation segment 205and the third electrostimulation segment during a second time interval.Other electrodes or electrostimulation pads or segments may be disposedat additional or alternative locations. For example, anelectrostimulation segment may be disposed on the lower portion 207, ina substantially similar manner as electrostimulation pad 204.

FIG. 25 is a lateral plan view of a knee brace assembly according to anembodiment of the invention. Knee brace 201 comprises an upper portion210 configured to engage with and be secured to a wearer's thigh; a band203 configured to engage with a wearer's knee in a semi-constrictivemanner; and a lower portion 211 configured to engage with and be securedto a wearer's calf. Upper portion 210 further comprises anelectrostimulation module 208 electrically coupled to an interface areaon upper portion 210 or lower portion 211. Upper portion 210 may furthercomprise a liner 202, such as an adjustable or segmented liner asdescribed herein, to allow the brace to conform to a wearer's anatomy ina comfortable manner. As described herein, liner 202 may furthercomprise electrodes electrically coupled to electrostimulation module208 to enable electrostimulation module 208 to deliver electrophysicalmodalities to a wearer.

Knee brace 201 may further comprise a band 203 coupled to the brace suchthat the brace is maintained in a substantially stable position and suchthat electrodes may be disposed at a plurality of locations around theanatomy of a user's knee. For example, band 203 may be coupled thehinging portion of knee brace 201 and elastically conform to thecircumference of a portion of the user's knee such that the brace isrotationally stable and translationally stable in the distal proximalaxis without causing excessive discomfort to a wearer. Accordingly, asurface is provided to adjustably position electrodes on a wearer's kneeanatomy and any electrodes positioned on the upper or lower braceportions are maintained in a stable position.

FIG. 26 is a lateral perspective view of a knee brace assembly worn on auser's leg according to an embodiment of the invention. As illustratedand described herein, the disposition of the upper cuff portion 206anterior of the wearer's thigh and the disposition of the lower cuffportion 207 posterior to the wearer's calf provide a rigid bracingsupport system that can impart a relieving force on a user's knee joint.Liner 202 may be an adjustable or segmented liner as described herein toprovide a conforming surface with the wearer's anatomy. Band 203 maycomprise an elastic or other type of resilient material coupled to thebrace hinge or other brace elements to provide positional stability anda surface upon which electrostimulation elements may be disposed.Various electrostimulation modules may be incorporated into such abrace. For example, the illustrated brace comprises anelectrostimulation element 204 incorporated into liner 202 andelectrostimulation element 205 incorporated into band 203. As describedherein, these electrostimulation elements may be configurable orinterchangeable according to a wearer-specific and condition-specificelectrophysical modality.

FIG. 27 illustrates two examples of thigh cuffs with electrostimulationunits according to embodiments of the invention. FIG. 27A illustrates athigh cuff with an integrated electrostimulation unit according to anembodiment of the invention. The integrated thigh cuff 206 comprises apower source 209, such as a battery, electrically coupled to anelectrostimulation unit 210. Electrostimulation unit 210 may comprise asignal generator, such as a programmable signal generator configured toprovide a predetermined electrophysical modality. Electrostimulationunit 210 is further coupled to electrodes, such as electrostimulationunits 204 and 205 as illustrated in FIG. 26, and is configured toprovide an electrical current according to a predeterminedelectrophysical modality. In some embodiments, such thigh cuffs orstimulation units may be interchangeable according to theelectrophysical modality provided. For example, a thigh cuff configuredto provide a TEJS treatment may be interchanged with a thigh cuffconfigured to provide SES treatment if a wearer's condition changes. Oras another example, the electrostimulation unit 210 may beinterchangeable within a cuff, such as through a removable panel.

FIG. 27B illustrates a thigh cuff with a detachable signal generatoraccording to an embodiment of the invention. In the illustratedembodiment, thigh cuff 206 comprises a receptacle 231 configured toslidably receive a detachable electrostimulation unit 208. Receptacle231 may further comprise an electrical contact 232 such thatelectrostimulation signals generated by electrostimulation 208 aretransmitted to electrostimulation pads or electrodes as describedherein. Alternatively, feature 232 could also be configured to functionas a snap-fit or latch mechanism to lock the electrostimulation unit 208in place. A faceplate 230 may be provided for insertion into receptacle231 when electrostimulation unit 208 is not in use or is not prescribed.Such a faceplate 230 may protect electrical contact/latch 232 from theenvironment and provide a smooth surface contour for thigh cuff 206 whenthe electrostimulation unit 208 is not in use or is not prescribed.

FIG. 28 shows a plan view and a lateral side view of anelectrostimulation pad electrode according to an embodiment of theinvention. Electrode 250 has a surface profile comprising an interfaceportion 252 and a connection portion 251. Interface portion 252 isconfigured to provide a conductive interface between the electrode andthe wearer's anatomy. Interface portion 252 has a profile shaped toserve a particular electrophysical modality. For example, asubstantially circular profile may be used to interface with a largemuscle group while a thinner or custom shaped profile may be used tointerface with a specific joint. Connection portion 251 is configured toallow an electrical connection to be formed between the electrode and anelectrostimulation unit.

The embodiment of FIG. 28 comprises three layers: (1) a conductiveinterface layer 253; (2) conductive middle layer 254; and (3) a backinglayer 255. Conductive interface layer 253 comprises a conductivematerial to allow electrostimulation signals to be transmitted to awearer's anatomy and to maintain such transmissions under normal wearingconditions. For example, conductive interface layer 253 may comprise aconductive hydrogel or elastomer that may be elastic, flexible, andconformable such that the electrode maintains contact along the entireinterface portion profile 252 during normal body movements.

Conductive middle layer 254 comprises an electrically conductivematerial to distribute the electrostimulation signals across theinterface portion 252 profile. In some embodiments, such as embodimentswhere the electrode is disposed on a rigid or semirigid portion of anorthotic device, the conductive middle layer 254 may comprise rigid orsemirigid conductive material. In other embodiments, such as embodimentswhere the electrode is disposed on an elastic band or other flexibleportion of an orthotic device, the conductive middle layer 254 maycomprise a flexible or elastic material. For example, the conductivemiddle layer 254 may comprise a carbon film or an elastic carbon filmthat allows the electrode to resiliently deform such that it can conformto a wearer's particular anatomy and maintain conformance during normalmotion. In still other embodiments, the conductive middle layer 254 canbe integral to or within the conductive interface layer 253.

Backing layer 255 provides a surface to attach the electrode to anorthotic device. For example, backing layer 255 might comprise anadhesive, such as a pressure sensitive adhesive, or one side of aVELCRO® adhesive system. In some embodiments, backing layer 255 mightcomprise an insulating material to ensure proper electrical flow and toavoid inadvertent contact with the conducting layers. In otherembodiments, the backing layer may be conductive or may have conductiveportions to facilitate electrical connection. For example, the backinglayer could comprise one surface of a hook and loop type system composedof conducting hooks and loops while the second surface of the conductivehook and loop system could be disposed on the orthotic device andelectrically coupled to the electrostimulation unit. Such a conductivehook and loop system might comprise a hook and loop system composed of aconductive material, or a hook and loop system composed of anon-conductive material coated with a conductive material. In theseembodiments, the electrostimulation circuit may be completed merely byattaching the electrostimulation pad to the orthotic device.

FIG. 29 illustrates a side view of an electrode disposed on an orthoticdevice according to an embodiment of the invention. Theelectrostimulation pad 250 is attachable to the orthotic device 258 suchthat an electrical connection can be formed between the device and thepad. Such an electrical connection may be formed using a connectionmember 257 comprising a conductive electrical contact 256 embedded in aninsulating material. In embodiments where the electrostimulation pad 250comprises an electrical connection portion 251, connection member 257may be connectable to connection portion 251. In such embodiments, theconnection portion 251 may be recessed in with respect to the interfaceportion 252, such that the pad has a substantially constant elevationafter electrical connection. For example, this may be achieved byreducing or eliminating the conductive interface layer 253 at theconnection point, such that the connection member 257 connects directlyto the conductive middle layer 254. In other embodiments, this may beachieved by compressive force imparted on the pad by connection member257 when engaged.

FIG. 30 is a plan view of an electrode disposed on a segmented lineraccording to an embodiment of the invention. As illustrated in the planview, connection member 257 forms an electrical connection withconnection portion 251. As described herein, segmented liner 258 may beresilient and adaptable to conform to a wearer's anatomy. Similarly, theelectrode 250 and connection member 257 may be resilient and adaptableto also conform to a wearer's anatomy. In the illustrated embodiment,connection member 257 is configured as described with respect to FIG.29. In other embodiments, connection member 257 may comprise other meansof electric connections. For example, electrical connection member 257may comprise a mating means to insertably receive connection portion251. Said mating means can comprise a socket, pin, contact-surface, orother connection geometry. Alternately, the mating means can be an arrayof pins that simply pierce into the connection portion 251.

FIG. 31 illustrates an electrode having a plurality of connectionportions according to an embodiment of the invention. As illustrated, aplurality of connection portions 251 and connection members 257 may beprovided for additional stability and to ensure a stable connection. Forexample, electrode 250 may be disposed on an elastic band, such as anelastic knee band as described herein, and may undergo frequentcontorting and stretching forces. Additionally, the use of multipleconnection portions 251 and connection members 257 may assist inproviding a uniform distribution of electrical energy throughout theelectrode. For example, in a large pad, such as when disposed on athigh, using a single connection member may result in electrical energybleeding off or concentrating in only a portion of the pad. Accordingly,multiple electrical connection portions 251 may be formed integrallyfrom the electrode layers such that a disruption in the electricalconnection at any one portion does not disrupt the transmission of theelectrostimulation signals.

FIG. 32 illustrates a cross-sectional view of an electrode according toan embodiment of the invention. In some embodiments, these electrodescan be integrated into such segmented liners as described herein. Forexample, a segmented liner 280 is attached with an electrode which mayhave a conductive layer 281 and an interface layer 282 disposed thereon.Conductive layer 281 may be formed to have a connection portion 283 toform an electrical connection with an electrostimulation unit throughcontacts 284 and 285. Electrical contacts 284 and 285 may be configuredsuch that segmented liner 280 may be adjustable and detachable, asdescribed herein. Conductive interface layer 282 may be truncated asshown in FIG. 32, or it may continue uniformly across the entire surfaceof electrode.

FIG. 33 illustrates a plan view of a further electrode 300 according toan embodiment of the invention. Electrode 300 may comprise an interfaceportion 301 and a connection portion 302. The electrode 300 may beformed integrally of three or more layers, as described herein. Theoutermost interface layer configured to interface with the wearer'sanatomy may have a removed space 303, such that the conductive layer isaccessible. In such embodiments, electrical connection may be farmedwith the middle conductive layer without direct connection to theconductive interface layer while avoiding contact between the wearer'sanatomy and the conductive middle layer. Accordingly, the electricalcharge is distributed evenly throughout the interface portion 301 priorto transmission through the wearer's anatomy.

FIG. 34 illustrates a lateral view of an electrode according to anembodiment of the invention. Segmented liner 315 allows an electricalconnection member 317 to interface with electrode 318. For example,connection member 317 may comprise a stem 319 and insulating portion 320configured such that conductive layers 321 or 322 make electricalcontacts through connection portion 323. Stem 319 is conductive, whileinsulating portion 320 insulates the user from accidental electricalcontact with stem 319 if electrode 318 is not installed. In someembodiments, Stem 319 may comprise a conductive coating deposited oninsulating portion 320, or a conductive ring attached to insulatingportion 320. Attachment methods can include mechanical assembly orinserting ring 319 into insulating portion 317 mold (insert-molding).Stem 319 can include a lead-connection portion 316, for connection toelectrostimulation device. For example, connection may occur viasoldering, snap, friction/press-fit, or other mechanical means.Electrode 318 may be integrally formed with segmented liner 315, or maybe detachable from the liner, for example through a mechanical oradhesive connecting layer 324. For example, a mechanical connectinglayer may be a Velcro®hook and loop system. In some embodimentsconductive layers 321 or 322 can be truncated as shown, or each (orboth) can extend across entire surface of electrode in order to completethe electrical connection to stem 319.

FIG. 35 illustrates a plan view of nesting electrodes according to anembodiment of the invention. Such nesting electrodes may be disposed onorthotic devices that are subject to dynamically changing profiles. Theillustrated electrode 351 has a circular interface portion 350 and acrescent or arcuate shaped connecting portion 352. This connectionconfiguration allows for some rotation in the x-y plane, y-z plane, andthe x-z plane without folding or breaking the electrical connectionbetween the electrodes. For example, a series of such nested electrodesmay be disposed on the inner surface of an elastic orthotic bandconfigured to be disposed around an elbow. Accordingly in this example,the normal movement of a wearer's elbow will not impede the transmissionof the electrostimulation signals to the wearer. The nested shape alsoallows for better material yields with less waste during manufacturing.

FIGS. 36A-C illustrate lateral views of an adjustable electrode andliner according to an embodiment of the invention. The main liner 400 isdisposed on an orthotic cuff, as described herein. For example, mainliner 400 may be integrally formed with a brace, or may be attached to abrace, for example through an adhesive or hook and loop means such asVelcro®. A liner segment 404 can be comprised of a loop portion 405, amiddle material layer 406, and a mounting layer 408. Said liner segment404 is attached to the main liner 400 such that liner segment 404 may bedisposed on main liner 400 only within a predetermined range 412. In theillustrated embodiment, tethers 402 provide this attachment. Tethers 402may comprise one or more structures configured to attach the linersegment 404 to the main liner 400, such as an elastic or an inelasticmaterial.

Main liner 400 further comprises a means to secure the liner segment404, such as a hook and loop system 403 and 405 disposed on facingsurfaces of main liner 400 and liner segment 404. For example, layer 403may comprise the loop portion and layer 405 may comprise a hook portion,such that a wearer's skin contacts the loop surface rather than the hooksurface.

The adjustable electrode and liner further comprises an electrode 424removably attached to the liner segment 404. As described herein,electrode 424 may comprise a backing layer 409, a conductive layer 410,and an interface layer 411. Backing layer 409 can be placed on mountinglayer 408. Backing layer 409 may be conductive or have a conductivecoating. In some embodiments, the electrical signal can be transmittedby a wire, which is not shown in this Figure. In some embodiments,electrode 424 may be configured to be removed and replaced, for exampleafter a predetermined period of wear or according to a changingelectrophysical modality. The main liner 400 may further comprise arecessed area 401 configured to receive the liner segment 404 andelectrode 424. The recessed area 401 may define the areas to which theliner segment may be secured. Recessed area 401 may further have a depthconfigured such that the liner segment 404 and electrode 424 form amatching or substantially matching surface with main liner 400 whenworn. In some embodiments, the electrode stands slightly proud of thesurrounding liner area to ensure good contact with skin.

In various embodiments, the electrode or liner segment may have adensity or hardness that varies from the remaining brace padding. Forexample, conductive interface portion 411 may comprise a conductiveelectrode gel, which may have a lower density than main liner 400.Accordingly, materials of varying densities or hardnesses may be used inconstruction of the liner segment and electrode such that the threelayer system comprising the main liner, liner segment, and electrode hasa different resiliency to the one layer system comprising the main lineralone. For example, liner segment 404 may be configured to have a middlematerial layer 406 with a different density or hardness as compared tothe main liner, to allow proper conformation. In further embodiments,the material densities may be configured according to different desiredcharacteristics. For example, the electrode may make better contact withthe wearer if the electrode liner portion is softer than the surroundingmain liner.

FIG. 37 illustrates a tethered segmented liner and electrode with anelectrical contact according to an embodiment of the invention. In theillustrated embodiment, features having numbers equivalent to thoseillustrated with regards to FIGS. 36 A-C are equivalent. The embodimentof FIG. 37 further comprises electrical contacts 415 and 416 andelectrical connector 417. Electrical contacts 415 and 416 are configuredsuch that when the segmented liner is attached to the main liner 404,electrical contacts 415 and 416 join and electrically couple thesegmented liner and electrode to the orthotic device. In someembodiments, electrical contact 416 may be configured such that nomatter where within the predetermined range 412 the segmented liner isdisposed, no portion of electrical contacts 416 is exposed to a wearer'sskin. Electrical connector 417 is electrically coupled to electricalcontact 415 and further electrically coupled to electrode 424.Accordingly, when electrode 424 is replaced, as described herein,electrical connection 417 allows the new electrode to be electricallycoupled to the orthotic device and electrostimulation unit. In anotherembodiment, liner segment 404 may be attached directly within the mainliner 400 without tethers.

The invention features improvements in relation to skin, skincare andgeneral fit. Since each segment is raised, there are spaces betweensegments and this allows air to circulate. General fit is improvedbecause the segments allow variations in the contour of the user's bodyto be accommodated. Furthermore, because the segments effectivelyprovide a non-contiguous surface to the skin of a user, movement of softtissue, such as muscle, adjacent to one segment is less likely to affectthe contact of another segment with the body of the user. Accordingly, amore secure fit is achieved.

Yet another improvement is that the segments tend to keep the supportstructure, or least edges of the support structure, away from the user'sskin. This assists in reducing irritation of the users skin by therelatively more rigid support structure.

While specific embodiments of the invention have been shown in thedrawings and described in detail it will be appreciated by those skilledin the art that various modifications and alternatives would bedeveloped in light of the overall teachings of the disclosure.Accordingly, the particular arrangements disclosed herein are meant tobe illustrative only and not limiting as to the scope of the invention,which is to be given the full breadth of the appended claims and in anyand all equivalents thereof.

While various embodiments of the present invention have been describedabove, it should be understood that they have been presented by way ofexample only, and not of limitation. Likewise, the various diagrams maydepict an example architectural or other configuration for theinvention, which is done to aid in understanding the features andfunctionality that can be included in the invention. The invention isnot restricted to the illustrated example architectures orconfigurations, but the desired features can be implemented using avariety of alternative architectures and configurations. Indeed, it willbe apparent to one of skill in the art how alternative functional,logical or physical partitioning and configurations can be implementedto achieve the desired features of the present invention. Also, amultitude of different constituent module names other than thosedepicted herein can be applied to the various partitions. Additionally,with regard to flow diagrams, operational descriptions and methodclaims, the order in which the steps are presented herein shall notmandate that various embodiments be implemented to perform the recitedfunctionality in the same order unless the context dictates otherwise.

Although the invention is described above in terms of various exemplaryembodiments and implementations, it should be understood that thevarious features, aspects and functionality described in one or more ofthe individual embodiments are not limited in their applicability to theparticular embodiment with which they are described, but instead can beapplied, alone or in various combinations, to one or more of the otherembodiments of the invention, whether or not such embodiments aredescribed and whether or not such features are presented as being a partof a described embodiment. Thus, the breadth and scope of the presentinvention should not be limited by any of the above-described exemplaryembodiments.

Terms and phrases used in this document, and variations thereof, unlessotherwise expressly stated, should be construed as open ended as opposedto limiting. As examples of the foregoing: the term “including” shouldbe read as meaning “including, without limitation” or the like; the term“example” is used to provide exemplary instances of the item indiscussion, not an exhaustive or limiting list thereof; the terms “a” or“an” should be read as meaning “at least one,” “one or more” or thelike; and adjectives such as “conventional,” “traditional,” “normal,”“standard,” “known” and terms of similar meaning should not be construedas limiting the item described to a given time period or to an itemavailable as of a given time, but instead should be read to encompassconventional, traditional, normal, or standard technologies that may beavailable or known now or at any time in the future. Likewise, wherethis document refers to technologies that would be apparent or known toone of ordinary skill in the art, such technologies encompass thoseapparent or known to the skilled artisan now or at any time in thefuture.

The presence of broadening words and phrases such as “one or more,” “atleast,” “but not limited to” or other like phrases in some instancesshall not be read to mean that the narrower case is intended or requiredin instances where such broadening phrases may be absent. The use of theterm “module” does not imply that the components or functionalitydescribed or claimed as part of the module are all configured in acommon package. Indeed, any or all of the various components of amodule, whether control logic or other components, can be combined in asingle package or separately maintained and can further be distributedin multiple groupings or packages or across multiple locations.

Additionally, the various embodiments set forth herein are described interms of exemplary block diagrams, flow charts and other illustrations.As will become apparent to one of ordinary skill in the art afterreading this document, the illustrated embodiments and their variousalternatives can be implemented without confinement to the illustratedexamples. For example, block diagrams and their accompanying descriptionshould not be construed as mandating a particular architecture orconfiguration.

1. An electrode for an orthotic device, comprising: a backing layerhaving an outer surface allowing the electrode to be attached to theorthotic device; a conductive layer configured to receive and distributean electrical current according to an electrophysical modality; aninterface layer configured to conform to a wearer's anatomy and toconduct the electrical current from the conductive layer to the wearer'sanatomy; and a connection member attached to the conductive layer andconfigured to electrically couple with an electrical contact disposed onthe orthotic device.
 2. The electrode of claim 1, further comprising amaterial layer configured to provide a predetermined compressibility. 3.The electrode of claim 2, wherein the predetermined compressibility isdetermined such that the compressibility of the electrode substantiallymatches the compressibility of a neighboring portion of the orthoticdevice.
 4. The electrode of claim 2, wherein the predeterminedcompressibility is determined such that the compressibility of theelectrode or the discrete liner segment is different than thecompressibility of a neighboring portion of the orthotic device.
 5. Theelectrode of claim 1, wherein the connection member comprises anintegral projecting portion of the conductive layer.
 6. The electrode ofclaim 5, wherein the connection member has a void configured to allowthe connection member to attach to a projecting electrical contactattached to the orthotic device.
 7. The electrode of claim 5, whereinthe connection member further comprises an integral projecting portionof the interface layer.
 8. The electrode of claim 1, wherein at least aportion of the backing layer is electrically conductive and theconnection member comprises the electrically conductive part of thebacking layer.
 9. The electrode of claim 1, wherein the connectionmember comprises an electrically conductive element projecting throughthe backing layer.
 10. The electrode of claim 1, further comprising aplurality of connection members electrically coupled to the conductivelayer.
 11. The electrode of claim 10, wherein the plurality ofconnection members are configured to distribute the electrical currentthroughout the conductive layer.
 12. An orthotic device system,comprising: a first support member adapted to be secured to a portion ofa first side of a joint; a second support member adapted to be securedto a second side of the joint; a means of connecting the first supportmember to the second support member a conformable, discrete linersegment attached to the first or second support member configured toprovide an attachment location for a first electrode; a first electrodedisposed on the liner segment configured to contact a first area nearthe joint; a second electrode configured to contact a second area nearthe joint; and an electrostimulation unit in electrical contact with thefirst and second electrodes and configured to provide an electrophysicalmodality to the leg, wherein the first or second electrode comprises abacking layer having an outer surface allowing the electrode to beattached to an orthotic device; a conductive layer configured to receiveand distribute an electrical current according to an electrophysicalmodality; an interface layer configured to conform to a wearer's anatomyand to conduct the electrical current from the conductive layer to thewearer's anatomy; and a connection member attached to the conductivelayer and configured to electrically couple with an electrical contactdisposed on the orthotic device.
 13. The system of claim 12, wherein theelectrode or the discrete liner segment further comprises a materiallayer configured to provide a predetermined compressibility.
 14. Thesystem of claim 13, wherein the predetermined compressibility isdetermined such that the compressibility of the electrode substantiallymatches the compressibility of a neighboring portion of the orthoticdevice
 15. The system of claim 13, wherein the predeterminedcompressibility is determined such that the compressibility of theelectrode or the discrete liner segment is different than thecompressibility of a neighboring portion of the orthotic device.
 16. Thesystem of claim 12, wherein the connection member comprises an integralprojecting portion of the conductive layer.
 17. The system of claim 16,wherein the connection member has a void configured to allow theconnection member to attach to a projecting electrical contact attachedto the orthotic device or the discrete liner segment.
 18. The system ofclaim 16, wherein the connection member further comprises an integralprojecting portion of the interface layer.
 19. The system of claim 12,wherein at least a portion of the backing layer is electricallyconductive and the connection member comprises the electricallyconductive part of the backing layer.
 20. The system of claim 12,wherein the connection member comprises an electrically conductiveelement projecting through the backing layer.
 21. The system of claim12, further comprising a plurality of connection members electricallycoupled to the conductive layer.
 22. The system of claim 21, wherein theplurality of connection members are configured to distribute theelectrical current throughout the conductive layer.